System for separating solids from a fluid stream

ABSTRACT

A system for separating solids from a fluid stream. The system includes a first separator device mounted to a container. The container includes a settling compartment and baffle plate module, with the initial settling compartment receiving the fluid from the first separator device. The fluid stream proceeds through the baffle plate module. The solids within the fluid stream will descend to the bottom of the container. A spiral blade is positioned at the bottom of the container, with the spiral blade adapted to convey solids to a first pump member. The speed of rotation of the spiral blade may be varied. The first pump member discharges the slurry to a second separator device. The second separator device will discharge the separated fluid stream into the baffle plate module. In one embodiment, the first separator device is a linear shaker and the second separator device is a cyclone separator and linear shaker mounted in tandem. The fluid exiting the baffle plate module may be directed into a mixing compartment, with the mixing compartment being part of the container. A method of separating solids from a fluid stream is also disclosed.

This application is a continuation-in-part of my co-pending applicationbearing Ser. No. 10/288,408, filed on 4 Nov. 2002, which is a divisionof application Ser. No. 09/846,974, filed on 1 May 2001, now U.S. Pat.No. 6,506,310.

BACKGROUND OF THE INVENTION

This invention relates to a system for treating fluid streams. Moreparticularly, but not by way of limitation, this invention relates to asystem and method for separating solids from a fluid stream.

In industrial applications, a fluid stream may contain solids. Thesolids may be suspended in solution. The particle sizes may range fromlarger diameter solids to extremely small diameter solids. As those ofordinary skill in the art will recognize, it is desirable to separatethe solids from the fluid. For instance, environmental regulations mayrequire that operators separate the solids from a slurry. Additionally,the operator may wish to reuse the base fluid, and hence, the fluid mustbe purged of solids.

As an example in the drilling industry, the well being drilled containscuttings from the subterranean well bore. The fluid being used to drillthe well is an expensive, chemically enhanced fluid. Therefore,operators wish to salvage the base fluid for reuse.

Regardless of the specific application, there is a need for a system andmethod to separate solids from fluid streams. Prior art devices sufferfrom many deficiencies. Prior art systems do not allow for adequateseparation of solids from the fluid. The present systems are notpackaged in an efficient and well-organized manner. The prior artsystems are bulky and can't be transported from site to site in a singlepackage. The present invention allows the packaging of the system on aframe that can be integrated with a trailer allowing for portability andmobility. Therefore, there is a need for a system and method toefficiently handle and separate solids from a fluid stream. There isalso a need to add bulk materials to a recently separated fluid stream.These needs, as well as many other needs, will be met by the novelinvention herein disclosed.

SUMMARY OF THE INVENTION

A system for separating solids from a fluid stream is disclosed. Thesystem comprises a first shaker adapted to a container, and a settlingtank positioned to receive the liquid discharged from the first shaker.The system will also include a first baffle module positioned at theoutput of the settling tank, with the first baffle module having adischarge opening. The fluid stream proceeds through the container in afirst direction. A spiral blade is positioned at the bottom of thecontainer, with the spiral blade adapted to convey the solids in asecond direction. The spiral blade will have a controller member thatvaries the speed of rotation of the spiral blade.

A first pump member is provided, with the first pump member receivingthe solids from the spiral blade, along with a first cyclone device thatreceives the discharge from the first pump member outlet and delivers aseparated fluid stream to the initial settling compartment. The solidsare discharged to a linear shaker. The linear shaker discharges theseparated fluid back into baffle plate module via the open top of thecontainer. In the preferred embodiment, the first baffle modulecomprises a plurality of baffle plates titled at an angle between 45degrees to 70 degrees.

Additionally, the system may contain a second pump member that has aninput line operatively associated to the bottom of the container toreceive the solids and an output line operatively associated with asecond tandem cyclone device and linear shaker. The liquid output fromthe cyclone device is channeled to the initial settling compartment andthe solids output from the cyclone device is channeled to the screen ofthe linear shaker. The collected solids from the screen of the linearshaker is collected to a bin and the fluid falls through the screen andinto the baffle plate module.

The system may also comprise a first weir positioned at the first bafflemodule and a second baffle module positioned adjacent the first bafflemodule. Additionally, the container may include a mixing compartmentoperatively connected to the discharge line from the baffle platemodules, the mixing compartment having a hopper and a mixing bladedisposed therein. In the preferred embodiment, the container is mountedto a base frame having a set of wheels for mobile transportation. A pumpmember is operatively associated with the mixing compartment, with thepump member having a suction line from within the mixing container and adischarge line within the mixing compartment.

A method of filtering a fluid containing solids is also disclosed. Themethod includes flowing the fluid into a first separating means forseparating the fluid from the solids and channeling the first cut fluidinto an initial settling compartment of a container. Next, the fluid ischanneled into a second compartment, with the second compartmentcontaining a plurality of baffle plates. Some of the solids remaining insolution will strike the baffle plates, which in turn will cause thesolids to settle to the bottom of the container.

The method further includes conveying the solids to a first dischargepump and discharging the slurry to a second separating means forseparating the fluid from the solids, and wherein the solids are furtherseparated from the fluid. Next, the fluid is discharged into the secondcompartment which in turn will cause the solids to travel through thebaffle plates thereby causing the suspended solids to strike the baffleplates. Some of the solids remaining in solution will settle to thebottom of the container and will in turn be conveyed to the firstdischarge pump. The solids can then be discharged to the secondseparating means thereby further separating the fluid from the solids.The fluid is exited from the container, and in particular, the fluidstream is exited from the baffle plate compartment.

In one embodiment, the first separating means comprises a linear shakerand the method includes collecting the solids into a bin. Additionally,the second separating means comprises a cyclone separator in tandem witha linear shaker device and the method includes collecting the solids inthe bin. The third separating means may comprise a cyclone separator intandem with a linear shaker means and the method includes collecting thesolids into the bin.

In one embodiment, the step of conveying the solids to the firstdischarge pump includes providing an auger blade placed in the bottom ofthe container and rotating the auger blade so that the solids are pushedto an inlet for the first discharge pump. The spiral blade can berotated at a variable speed in order to vary the solids concentration ofthe slurry to the cyclone separators. In the preferred embodiment, thebaffle plates are disposed at an angel of between 45 degrees to 70degrees. Additionally, the method may further comprise mixing anadditive and/or bulk material to the fluid within a mixing compartment.The method may also include suctioning from either the container ormixing compartment and pumping back into the mixing compartment in orderto mix the fluid stream with an additive.

An advantage of the present invention includes having a modular designwherein a component of the system may be added or removed from thesystem. Another advantage is the system may be transported easily fromone location to another location. For instance, the frame may be liftedvia a crane onto vessels, barges, flat beds, etc. Also, the frame mayinclude wheels so that the entire system can be transported via avehicle such as a truck.

Another advantage is that the novel system and method will remove solidsfrom five (5) microns and larger in some applications. Still yet anotheradvantage is that the system allows for redundancies in that the fluidstream is introduced to multiple separation devices such as the linearshaker, weir, baffles, cyclone separators, settling tanks, etc.Additionally, the fluid stream can be continuously recycled through thesystem until the desired level of filtration is achieved.

Further, it is desirable to have the solids thus collected to beessentially fluid-free. Another advantage is that the solids thusrecovered contain very little in-situ fluid.

A feature of the present invention includes having a linear shaker thatseparates large diameter solids from the fluid stream. Another featureis the option to use other types of shakers, such as orbital shakersthat can also separate small diameter solids from the fluid stream. Yetanother feature is the mixing compartment that can be added to thesystem for the mixing of bulk materials and/or additives to the fluidstream.

Still yet another feature includes use of an auger type of device forconveying the solids to a pump member. In the preferred embodiment, theauger type of device is a spiral blade without the shaft. The speed ofthe rotation of the auger blade can be varied depending on the nature ofthe slurry and the desired process rate of the fluid stream. Thus, afeature includes decreasing or increasing the rotation rate of thespiral blade in order to meet processing rate goals. Another featureincludes use of baffles in a baffle module, with the baffle plates beingtilted to maximize the impact of the suspended solids during fluid flowas well as to provide the proper orientation for fluid flow through thecontainer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of the preferred embodiment of the presentinvention.

FIG. 2 is a side perspective view of the preferred embodiment of thepresent invention.

FIG. 3 is a top perspective view of the preferred embodiment of thepresent invention as seen in FIG. 2.

FIG. 4 is a front perspective view of the preferred embodimentillustrated in FIG. 2.

FIG. 5 is a three dimensional perspective view of the preferredembodiment of FIG. 2.

FIG. 6 is an illustration of the linear shaker of the present invention.

FIG. 7 is an illustration of the hydrocyclone of the present invention.

FIG. 8 is a cross-sectional view of the system taken along line 8-8 inFIG. 2.

FIG. 9 is a partial sectional view of the system taken along line 9-9 inFIG. 2.

FIG. 10 is a schematic diagram of the most preferred embodiment of thisinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a schematic diagram of the preferred embodimentof the present invention will now be described. The system 2 seen inFIG. 1 includes a container seen generally at 4. The container 4 hasgenerally a bottom 6, two side walls, an open top, and two end walls.The two side walls and bottom 6 are configured in a “V” bottom shape asis well understood by those of ordinary skill in the art.

In a first compartment within the container 4, there is contained aninitial settling compartment 8. The initial settling compartment 8 hassituated above it the linear shaker 10, and wherein the linear shakeroriginally receives the fluid stream. The linear shaker 10 iscommercially available from Fluid Systems, Inc. under the name LinearShaker. The linear shaker 10 is sometimes referred to as the scalpingshaker since it makes the initial cut i.e. initially scalps the fluidstream of solids. It should be noted that the general fluid flow orsolids flow through the system 2 is denoted by the flow arrows.

The fluid stream initially flowing over the scalping shaker 10 will havethe solids suspended therein. The fluid stream may have originated froman oil and gas well bore, a directional bore hole being drilled forhighway and/or bridge construction, waste streams from industrialapplications, waste water treatment, tank cleaning, utilityconstruction, etc. The invention can be used for any application wherethe operator wishes to separate and segregate the solids from a fluidstream.

The scalping shaker 10 will make an initial cut of the solids from thefluid stream. As those of ordinary skill will appreciate, the shaker 10has a dual output, with the first output being primarily solids and thesecond output being primarily the fluid stream. The larger solids anddebris are screened and discarded off the side of the tank to a bin 11.Nevertheless, the fluid stream from the second output will continue tohave solids suspended therein. As seen in FIG. 1, the solids screenedwith the shakers are denoted by the arrows AA. The fluid which fallsthrough the screen is denoted by the arrows BB.

As those of ordinary skill in the art will appreciate, separationtechniques using shakers and cyclone separators are efficient but notperfect. In other words, by running the fluid streams through eachseparator means, a portion of the solids is removed during each cut. Thelarger diameter solids are removed first, followed by successivelysmaller diameter solids. The system herein disclosed allows for certainredundancies in order to achieve a desired level of separation.

In the embodiment depicted in FIG. 1, the container 4 will also containan underflow weir 12 positioned within the container, with the underflowweir 12 having an opening extending from the tank bottom 6 to the weir12 that is two feet wide. Thus, the fluid will travel through the spaceindicated by the numeral 14. The baffle plate module, which is seengenerally at 16, is positioned to receive the fluid stream from theinitial settling compartment 8. The baffle plate module 16 comprises aplurality of baffle plates seen generally in FIG. 9 as plates 16 a, 16b, 16 c, 16 d, 16 e, 16 f, 16 g, 16 h, 16 i. The baffle plates aretilted at a preferred angle of between 45 degrees to 70 degrees relativeto the horizontal ground reference level, with a most preferred angle of60 degrees as seen in FIG. 1. The baffle plates are tilted so that asthe fluid stream flows through the container, the suspended solids willstrike the baffle plates, decreasing the velocity of the solids andallowing gravity to force the solids to the bottom 6. As shown in FIG.1, the baffle plates are tilted in the direction of the fluid flowthrough the container 4. The solids which fall to the bottom may bereferred to as a slurry since the solids still contain an in-situ fluid.

FIG. 1 depicts the second baffle plate module 22 that is arrangedimmediately following the first baffle plate module 16. As illustratedin FIG. 9, the baffle plate module 22 contains a plurality of baffleplates: 22 a, 22 b, 22 c, 22 d, 22 e, 22 f, 22 g, 22 h, 22 i. In thepreferred embodiment, the baffle plates 22 a-22 i are tilted from 45degrees to 70 degrees, with a most preferred angle of 60 degrees,similar to the baffle plates 16 a-16 i.

Returning to FIG. 1, the baffle plate modules 16 and 20 may bemanufactured independently and then inserted into the container. Thebaffle plate modules 16, 20 can then be attached to the container viaconventional methods such as welding means, nuts and bolts means, etc.Also included in the embodiment shown in FIG. 1 is the overflow weir 24,with the overflow weir 24 having an opening at its top end, which in theembodiment shown in FIG. 1, the opening is approximately four feet wide.The fluid flow will occur through the opening area denoted by thenumeral 26. The opening 22 in turn leads to the mixing compartment thatwill be described later in the specification.

The bottom 6 contains a means for conveying 30 the solids to an exitline 32. In the preferred embodiment, the conveying means 30 will be anauger, and in the most preferred embodiment, the conveying means 30 isan auger blade without the inner shaft i.e. spiral blade. The shaftlessspiral blade is commercially available from Martin Sprocket & Gear, Inc.under the name Shaftless Screw Conveyor. Hence, with the rotation of theblade via motor 33, the solids are advanced to the exit 32.Additionally, in the preferred embodiment the motor 33 will becontrolled by a variable frequency drive (VFD) so that the speed ofrotation may be varied. Thus, the operator may vary the speed ofrotation so that the spiral blades may convey more solids to pumps 36and 38 (in the case of increasing rotation speed), or alternativelyconvey less solids to pumps 36 and 38 (in the case of decreasingrotation speed). In other words, by increasing rotation, more solids aredelivered to the cyclones via pumps 36 and 38, and by decreasingrotation, less solids are delivered to the cyclones via pumps 36 and 38.The operator may vary the speed according to the particular processingrate needs and system requirements of specific separation jobs. In thepreferred embodiment, the motor is an electric motor that iscommercially available from Marathon Inc. under the name Electric Motor.

As those of ordinary skill in the art will recognize, the fluid andsolids collected from the exit 32 may be referred to as a slurry. It isdesirable to separate the fluid from the solids. A dual object of thepresent invention is to produce solids that are essentially free ofwater and produce a fluid that is essentially free of solids.

In accordance with the teaching of this invention, the slurry beingforced from the exit 32 are directed to a separating means 34, which inthe preferred embodiment comprises a bank of hydrocyclones 34 a and alinear shaker 34 b. The hydrocyclone is commercially available fromKrebs Engineering, Inc. under the name Cyclone, and as noted earlier,the linear shaker 34 is commercially available from Fluid Systems, Inc.

Thus, the pump 36 will receive the mixture of solids and fluid and pumpit to the separator means 34 via the output line 36 a wherein theseparator means 34 will separate the larger solids and debris that arescreened and discarded to the bin 11. It should be noted that the tandemcyclone 34 a and linear shaker 34 b operation will be described ingreater detail later in the application.

The liquid output from the cyclone separator means 34 a is directed backinto the container 4 via the line 164 a, into trough seen generally at37, and into initial settling compartment 8. With reference to thelinear shaker 34 b, the fluid denoted by the BB arrows that fallsthrough the shaker screen is directed into the top open area of thecontainer 4 and in turn into the baffle plate modules. Therefore, thefluid is continuously cycled through the process, as noted earlier. Thepump 36 is commercially available from Mission Inc. under the nameCentrifugal Pump. In the preferred embodiment, the pumps are driven byan electric motor, and therefore, the pumps with the operativelyassociated driver motors may be referred to as electric pumps. Theelectric motor is commercially available from Marathon Inc. under thename Electric Motor. It should be noted, however, that it is within thescope of the present invention to have hydraulic powered pump meansand/or diesel powered pump means.

A second electric pump 38 is also shown, with the second pump 38 beingessentially identical to the first pump 36. The operator may choosepumps with specific capacities. As by example and for illustrationpurposes only, pump 36 may be a six inch suction and a five inchdischarge and pump 38 may be a six inch suction and a five inchdischarge. The second pump 38 is added so that the output capacity isincreased in the case where the quantity and processing rate of thefluid stream is important. In other words, when the output rate from thesystem 2 needs to be increased, the second pump 38 can be utilized toincrease the processing rate. The second pump 38 receives as an intakefrom the point denoted at 38 a which is downstream of the intake forfirst pump 36. At the point 38 a, the solids tend to be smaller indiameter since the solids are collected at a point (38 a) in thecontainer where the larger solids have already been separated.

The second pump 38 will pump the slurry to the second separator means 40that includes the tandem cyclone separator 40 b and the linear shaker 40a. The separator means 40 will process the fluid stream in a similarmanner as with the separator means 34. The liquid output from thecyclone separator means 40 b is directed back into the container 4 vialine 164 b, the trough 37 and into initial settling compartment 8. Withthe reference to the linear shaker 40 a, the fluid (denoted by the BBarrows) that falls through the shaker screen is directed into the topopen area of the container 4, and in turn, into the baffle platemodules. Therefore, the fluid is continuously cycled through theprocess, as noted earlier

As noted in FIG. 1, pump 36 receives the slurry from exit 32 anddischarges to the separator means 34 via discharge line 36 a. The pump38 receives the slurry from exit 38 a and discharges to the separatormeans 40 via discharge line 44.

The flow of the fluid stream enters through the scalping shaker 10 asdenoted by the arrow 46. The fluid that flows through the screen ofshaker 10 is denoted by the arrows BB. The arrows within container 4represent the general fluid stream flow. As solids are knocked andseparated from the fluid within the baffle plate module, the solidssettle to the bottom and the conveyor means moves the slurry as denotedby the arrow 50. Note that the fluid flow is generally opposite thedirection of the slurry flow.

Once the fluid stream has been processed through the container 4, thefluid stream will exit the overflow weir 24 via the opening 26 asdenoted by the arrow 52. The overflow weir 24 will direct the fluidstream into the mixing compartment 54. The mixing compartment 54 willcontain mixing blades. The mixing hopper 56 is also operativelyassociated with the mixing compartment 54, with the mixing hopper 56allowing for the introduction of bulk materials, chemical additives, andso on as is well understood by those of ordinary skill in the art. Themixing compartment 54 has contained therein a pair of mixing propellers98, 100 for mixing additives and/or bulk material, for instance, intothe fluid stream. The additives can be added via the mix hopper 56wherein the mix hopper 56 is fed into the line 82 that in turndischarges into the mixing compartment 54.

A pump means 58 will be operatively associated with a first intake line60, with the first intake line being operatively associated with thecontainer at the second end adjacent the overflow weir 24. The pumpmeans 58 is commercially available from Mission Inc. under the nameCentrifugal Pump. The intake line 60 suctions from the fluid stream thathas been processed through the system. The pump means 58 will have asecond intake line 62, with the intake line 62 being positioned tosuction from the mixing compartment 54.

The pump means 58 will have a first discharge line 64, with the firstdischarge line leading into the mixing compartment 54. The firstdischarge line 64 will have operatively associated therewith output jetnozzles 66 which are commercially available from Halco Inc. under thename Mud Guns. Thus, the pump means 58 will be able to suction from thecontainer via line 60 essentially clean fluid and pump into the mixingcompartment via line 64, with the mud guns 66 allowing for the jetmixing of the fluid stream within the compartment 54. The pump 58 willalso be able to pump from the mixing compartment and then dischargethrough the mud guns 66.

A valve means 68 for opening and closing the line 60 is included as wellas a valve means 70 for opening and closing the line 64. A seconddischarge line 72 may be included, with the line 72 having a valve means74 for opening and closing the line 72. The line 72 may discharge to astorage bin, for instance.

The system 2 will also contain the electric pump means 76, with the pumpmeans 76 having a suction intake line 78 that suctions from inside themixing compartment 54. The pump means 76 is commercially available fromMission Inc. under the name Centrifugal Pump. The pump means 76 willhave a discharge line that branches into three separate lines, namely afirst discharge line 80 (same as line 64?) that leads to the mud guns 66previously described, a second discharge line 82 that leads to themixing hopper 56, a third discharge line 83 to the mixing compartmentand discharge line 83 to the mixing compartment and discharge line 84.The valve means 86 is included for directing the discharge stream toline 64, or to simply close the line. The discharge line 84 containsvalve means 88 for opening and closing line 84 and discharging to astorage bin, for instance. Valve means 89 is included for opening andclosing line 82.

Referring now to FIG. 2, a side view of the preferred embodiment fromFIG. 1 will now be described. It should be noted that like numeralsappearing in the various figures will refer to like components. As notedearlier, the container 4 consist of a V-shaped vessel 4, with thescalping shaker 10 mounted above the initial settling compartment 8. Thefirst baffle plate module 16 and second baffle plate module 22 arepositioned within the vessel 4. From the second baffle plate module 22,the fluid stream will exit via the exit 26 (not shown) into mixingcompartment 54 as previously described.

The slurry that is being collected at the bottom of the vessel will beconveyed via the conveying means 30 (not shown in FIG. 2) for conveyingthe solids from one end to the other end, which in the preferredembodiment is a spiral blade, as noted earlier, and is similar to anauger without the inner shaft.

FIG. 2 also depicts the first electric pump means36 that collects theslurry exited from the bottom of the vessel via the conveyor means.Hence, the pump means discharges to the line 36 a which in turn leads tothe hydrocyclone separator 34 a (also referred to as cyclone separator).As noted earlier, the cyclone separator 34 a is commercially availablefrom Krebs Engineers, Inc. under the name Krebs Cyclone.

As is understood by those of ordinary skill in the art, the cycloneseparator 34 a receives the slurry and will separate the solids from thefluid within the slurry. The cyclone separator works particularly wellin separating sand and silt from fluid streams. The underflow or solidsdischarged out of the cyclone is then screened by the linear shaker 34 bin order to dewater or dry the discharged solids before they arediscarded off the side of the tank to the bin 11. The overflow or fluiddischarge out of the cyclone 34 a is discharged into the trough 37 thatcarries it back to a discharge point underneath the linear shaker 10which in turn is delivered to the initial settling compartment 8. Thus,the solids are disposed of to a bin 11 while the fluid is conveyed backto the vessel, and in particular, back into the baffle plate modules 16,22.

In the embodiment illustrated, the mixing compartment 54 is integratedonto the same frame together with the vessel 4.

The embodiment shown in FIG. 2 also contains the electric pump means 76that pumps to the line 64 or line 82. The pump 76 may also be used topump from the mixing compartment 54 via line 84 in the event theoperator wishes to pump the fluid stream out of the mixing compartment54.

The system has as a frame 106 to which all of the previously mentionedcomponents are attached. As part of the frame, a set of wheel means 108for transporting the system may be included. The frame may also includea trailer hitch device (shown generally at 110), with the trailer hitchdevice being capable of use with a vehicle (such as an 18-wheeler) sothat the entire system may be hauled from one location to anotherlocation. In another embodiment, components may be attached to a frame,and the frame can be lifted with a crane or winch truck, so that thesystem may be transported via a ship or vessel in remote environments.As noted earlier, an advantage of the present system is the modularityof the system and the ability to transport the system in a package thatis compact and condensed.

Also included will be the stairs 111 that an operator can use to mountthe system. FIG. 2 also depicts the hand railings 112 for use byindividuals while working, inspecting, monitoring, and/or repairing thesystem.

With reference to FIG. 3, a top view of the preferred embodimentdepicted in FIG. 2 will now be described. The scalping shaker 10 willmake a first separation (cut) of solids from the fluid stream. The fluidwill then descend from the wire mesh screen 130 of shaker 10 to thesettling compartment 8. As noted earlier, the fluid flows to the firstbaffle plate module 16 and then into the second baffle plate module 22.

The solids will segregate to the bottom as previously described. Thus,the pumps 38 and 36 will pump the slurry to the cyclones 34 a and 40 bwhich will act to further separate the solids from the fluid stream. Theliquid output from the cyclone 34 a will be fed via line 164 a to thetrough 37 back into the vessel for continuous processing. The liquidoutput from the cyclone 40 b will be fed via line 164 b to the trough 37back into the vessel for continuous processing. The solids from thecyclone 34 a will be directed to the linear shaker 34 a, and inparticular to the wire mesh screen 132 for dewatering the solids. Thesolids from the cyclone 40 b will be directed to the linear shaker 40 a,and in particular with the wire mesh screen 134 for dewatering thesolids.

FIG. 3 also illustrates the placement of the mixing compartment 54. Asshown, the mixing hopper 56 is placed above the mixing compartment 54for positioning the entry of any additives into the compartment. Theadditives enter the hopper 56 and then the mixer 136 with blades 98, 100will mix the components as necessary. The eurodrive mixer 136 iscommercially available from Del Corporation under the name Mixer. Anadvantage of the present invention is that fluid that is cleaned as perthe novel method can then be used as the mixing fluid within the mixingcompartment 54.

In FIG. 4, the drawing illustrates the system of FIG. 2 in a front view.Thus, FIG. 4 illustrates the pair of cones that make up the cycloneseparators 40 b and the linear shaker 40 a. The eurodrive mixer 136 isdepicted positioned on top of the mixing compartment 54. The mixinghopper 56 is shown, along with the discharge line 82. The pump 76 isshown having the discharge line 82 extending therefrom. The pump motor138 is shown, with the pump motor being an electric drive in the mostpreferred embodiment. FIG. 4 also depicts the wheels 108, stairs 111,and handrails 112 for a walk way are also included.

Referring now to FIG. 5, a perspective view of the preferred embodimentof FIG. 2 will now be described. The FIG. 5 depicts the scalping shaker10 that is positioned above the initial settling tank 8. The fluidstream then flows into the first baffle plate module 16 and into thesecond baffle plate module 22 as previously noted. In the preferredembodiment, the conveyor means will be rotated via an electric motor 33so that the speed of rotation of the motor's shaft can be varied whichin turn will vary the speed of rotation of the spiral blade. By varyingthe speed of rotation of the spiral blade, the concentration of solidsconveyed by the spiral blade can vary. The fluid containing the solidswill be delivered to the cyclone separator 34 a via the pump 36 and thepump 38 (pumps 36 and 38 are not shown in this view) will pump theslurry to cyclone separator 40 b as noted earlier.

Once the fluid stream exits from the baffle plate module 22, theoperator may direct the fluid stream into the mixing compartment 54. Thefluid stream exiting the second baffle plate module 22 is essentiallyfree of suspended solids. Generally, the system will remove solids fromfive (5) microns and larger from the fluid system.

Hence, the operator may wish to condition the fluid by adding certainmaterial so that the fluid stream has certain desirable properties. Forinstance, if the operator is using the fluid stream as a drilling fluid,the operator may wish to add chemical additives to inhibit the swellingof clays, or to simply weight the fluid so that the column of fluidwithin the well bore exerts a greater hydrostatic pressure. Regardlessof the specific application, the operator may mix the bulk materialand/or additives by pouring the additives into the hopper. The fluidstream can be channeled into the mix compartment 54 via the pump means58. It should be noted that FIG. 5 depicts the pump means 58 and theelectric drive motor 58 a that drives the pump means 58 as is wellunderstood by those of ordinary skill in the art. The intake line 60 isshown for pump 58 along with the output line 64 and the valve 74. Pump76 can intake from line 78 and discharge to either line 64, line 84, orline 82. Valve means 86 will direct flow to line 64.

The linear shaker 10 will now be described. FIG. 6 is an illustration ofthe linear shaker 10. Basically, the scalping shaker 10 will receive adischarge of the slurry onto the wire screen 130, with the screen beinga certain mesh i.e. opening. As understood by those of ordinary skill inthe art, the shaker screen is vibrated thereby knocking and shaking theslurry so that the solids are caught on the top side of the screen andthe fluid falls below. The screen is vibrated and oscillated at highfrequencies as is well understood by those of ordinary skill in the art.In the preferred embodiment, the discharge is in two parts: the firstpart is the solids caught by the wire mesh screen with the flow off thescreen 130 being denoted by the arrow AA, and wherein the solids arefunneled to a bin; in the second part, the fluid stream falls throughthe wire mesh screen denoted by the arrow BB, and wherein the fluidstream can then be directed back into the baffle plate module. The frameof the shaker 120 is mounted via conventional means, such as welding orbolting, to the frame 107 of the system, with the chassis of the shakerhaving spring leg mounts 144 to attach the shaker and adsorb thevibrations as is well understood by those of ordinary skill in the art.

In FIG. 7, the cyclone 34 a is shown. As shown, a pair of cones, namely146, 148 are depicted. In accordance with the teachings of thisinvention, the multiple cones may be used depending on the desired flowrate being processed. Some embodiments will use a dozen cones. In thealternative, only a single cone may be used. Some factors in decidingthe number and size of cones employed includes the processing rate, thedesired separation diameter of the solids, the nature of the solids,etc. Hence, it is within the scope of this invention that a bank ofcones may be used with an individual linear shaker.

Generally, the fluid stream with embedded solids enters through theinlets 150 via the line 36 a. The fluid stream is injected into the coneunder pressure. As is well understood by those of ordinary skill in theart, the cone shape container results in a centrifugal force created bythe incoming fluid stream. The effect is to force solids to the innerwall of the cyclone. The cleaned liquid from the center of the swirlingliquid mass flows out of the top section 152, 154 of the cyclone, andthe solids spin downward to the outlets 156, 158. In the design of thepresent invention, the solids (denoted by the arrows 160) discharge tothe wire mesh screens of the linear shakers as previously described. Thefluid (denoted by arrow 162) is directed back into the vessel via thedischarge line 164 a, with the discharge line leading to the trough 37.

FIG. 8 is a cross-sectional view of the system taken along line 8-8 ofFIG. 2. Thus, the cyclone 40 b is shown with the discharge line 164 bdischarging fluid (arrow 162) to the trough 37, with representativesmall diameter solids seen in the trough 37. The fluid with somesuspended solids within the tilted baffle plate module 22 is also shown.FIG. 8 also depicts the fluid (denoted by arrow BB) that has fallenthrough the screen of the shaker 40 a into the open top area of vesselwhich leads to the baffle plate module. The spiral blade 30 is alsoshown disposed at the bottom of the V-shaped container 4. The solids AAis shown being dispensed from the shaker 40 a which will be deposited tothe bin. The discharge line 44 from pump 38 is also shown. The container4 mounted on the frame 106 is also depicted.

FIG. 9 depicts a partial cross-sectional view of the system taken alongline 9-9 of FIG. 3. This view depicts the discharge line 36 a from pump36 to the cyclone 34 a and the discharge line 44 from pump 38 to thecyclone 40 b. The baffle plates of module 16 are denoted by the numerals16 a, 16 b, 16 c, 16 d, 16 e, 16 f, 16 g, 16 h, 16 i. The second baffleplate module 22 is also illustrated, with the baffle plates beingdenoted by the numerals 22 a, 22 b, 22 c, 22 d, 22 e, 22 f, 22 g, 22 h,22 i. The line 64 which contains the mud guns 66 is also shown. Theshaftless spiral blade 30 is also pictured.

The intake line 62 which is inside the mixing compartment 54 is shown,with the intake line 62 being connected to the pump 58 (not shown inFIG. 9). Within the mixing compartment 54 is the mixing blades 98, 100that is driven by mixer 136. The mixing guns 66 are operativelyassociated with the discharge line 64. The open area 26 from theoverflow weir 24 allows the fluid stream to enter the compartment 54, aspreviously stated. The mixing hopper 56 is also depicted.

One of the features of the present invention is the modularity of thecomponents allows for multiple shakers and cones to be placed upon thevessel 4. The rate at which the operator seeks to clean a fluid streamwill, at least in part, determine the number of separating means thatare ultimately employed. Hence, with very large processing volumes, theoperator can place a scalping shaker and two tandem cyclone-shakers (asshown in the FIGS. 1 through 9 of this application). Alternatively, theoperator can place a scalping shaker and three tandem cyclone/shakers.In another option, the operator can place a scalping shaker and only asingle tandem cyclone/shaker.

As an example of the number of separators and pumps required, thecyclone separator pump may be sized to feed a bank of cyclones capableof handling a flow rate of 2000 gallons per minute (gpm). If more than1500 gpm is required however, it is recommended that a third linearshaker, 40 a, be used in order to split the cyclones so that theydischarge over two linear shakers in order to sufficiently dewater theunderflow. If flow rates greater than 2000 gpm are desired then anotherfeed HCFP2-pump 38 can be installed directly behind feed HCFP1 pump 36and feed a second bank of hydrocyclones, 40 b, capable of making aparticle size cut that is the same or finer than cyclone 34 a. Animportant feature to the cleaning efficiency of the system is the ratioof cleaning rate to flow rate through the system. If the fluid stream ispumped to linear shaker 10 at a rate of 500 gpm and is processed throughthe hydrocyclones 34 a and 40 b at a rate of 2000 gpm, then the cleaningto flow ratio is 4:1. The system can be set up to maximize the cleaningto flow ratio simply by increasing the number of cyclones and linearshakers and properly sizing the feed pumps.

A second embodiment is shown in FIG. 10, which is the most preferredembodiment of the present invention. This second embodiment of FIG. 10,like the embodiment of FIGS. 1 through 9, has applications for oil andgas well drilling, utility construction, waste water treatment, tankcleaning, waste minimization, dredging, tunneling, etc. In short, anyprocess requiring the removal of heavy solids from a fluid stream.

In the preferred embodiment of FIG. 10, the fluid stream enters tank 4through linear shaker 10 where larger solids and debris are screened anddiscarded off the side of the tank. Any fluid and solids passing throughthe screen on linear shaker 10 enter tank 4 and must flow underunderflow weir/“possum belly” 12. Screw conveyor (shaftless or withshaft) 30 conveys any solids that settle to the bottom of tank 4 at thispoint in the opposite direction of the fluid stream flow to hydrocylconefeed pump 36 suction. Any solids which stay in suspension and continueon with the fluid stream enter the tilted plate baffle system (16 and22) which forces the solids to settle to the bottom of tank 4 by thesolids striking the tilted plates, decreasing their velocity andallowing gravity to force them to the bottom so that they are leftbehind by the fluid stream. When these solids settle to the bottom oftank 4, screw conveyor (shaftless or with shaft) 30 conveys them back tohydrocylcone feed pump 36 suction. Hydrocylcone feed pump 36 pumps thesettled solids slurry to hydrocyclones 34 a. Hydrocyclones 34 a is abank of hydrocyclones that has been properly sized to remove theundesirable solids from the fluid stream. The underflow or solidsdischarge out of hydrocyclones 34 a is then screened by linear shaker 34b in order to dewater or dry the discharge solids before they arediscarded off the side of the tank. The overflow or fluid discharge outof hydrocyclones 34 a is discharged into a pipe that carries it back toa “possum belly” that fills and overflows over the tilted plate bafflesystem (16 and 22). Any suspended solids not removed on the first passthrough hydrocyclones 34 a will settle, screw conveyor (shaftless orwith shaft) 30 will convey them to hydrocylcone feed pump 36 suction,and hydrocylcone feed pump 36 will pump them to hydrocyclones 34 a. Anysolids remaining will continue in this cycle until they are finallyremoved by hydrocyclones 34 a, screened by linear shaker 34 b, anddiscarded off the side of the tank.

Typically, lighter solids will take longer to settle; therefore, thesuction of hydrocyclone feed pump 38 is located farther down in the flowstream, past underflow weir/“possum belly” in order to remove theselighter, finer solids. Hydrocyclone feed pump 38 pumps the settledslurry to hydrocyclones 40 a is a second bank of hydrocyclones properlysized to remove the finer solids left in the fluid stream. The underflowof hydrocyclones 40 a is then screened by linear shaker 40 a, dewatered,and discarded off the side of the tank. The overflow of hydrocyclones 40a is discharged into a pipe and is carried back to the same “possumbelly” as the overflow of hydrocyclones 34 a and flows through thetilted plate baffle system (16 and 22) again.

The fluid stream, which continues to flow through tilted plate bafflesystem (16 and 22) to the end of tank 4 opposite the location of linearshaker 10, may exit tank 4 by one of two methods chosen by the operator.In the first method, the flow stream exits tank 4 by overflowingoverflow weir 26 into mixing/chemical treatment tank 54. Asmixing/chemical treatment tank 54 fills with the clean fluid from tank4, then mixing pump 76, mixing hopper 56, mixer 136, and mud guns 66 canbe used to mix additional fluid in the case of drilling mud or they canbe used to chemically treat the fluid in the case of tank cleaning wherefurther treatment of the fluid by a centrifuge may be required. Oncemixing and/or treatment has taken place transfer pump (58) may be usedto transfer the fluid from mixing/chemical treatment tank 54 to whereverthe operator may desire. The second method by which the cleaned fluidmay exit tank 4 is by being pumped by transfer pump (58) intomixing/chemical treatment tank 54 through mud guns 66. Oncemixing/chemical treatment tank 54 fills, clean fluid will overflowoverflow weir 26 back into tank 4. Mixing pump 76, mixing hopper 56,mixer 136, and mud guns 66 may be used to mix additional fluid orchemically treat the clean fluid as in the first method. Transfer Pump76 or a remote portable pump may be utilized to transfer the clean fluidfrom mixing/chemical treatment tank 54 to wherever the operator maydesire.

As noted earlier, the key to the cleaning efficiency of the system isthe ratio of cleaning rate to flow rate through the system. As per theteaching of this inventor, if the fluid stream is pumped to linearshaker 10 at a rate of 500 gpm and is processed through thehydrocyclones at a rate of 2000 gpm then the cleaning to flow ratio is4:1. The system can be set up to maximize the cleaning to flow ratiosimply by increasing the number of hydrocyclones and linear shakers andproperly sizing the feed pumps. Systems capable of flow rates in excessof 3000 gpm are often utilized in large dredging applications.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the scope of the invention that isintended to be limited only by the scope of the appended claims and anyequivalents thereof.

1. A system for separating solids from a fluid stream, said systemcomprising: a first linear shaker device adapted to a container, saidfirst linear shaker having a liquid output, and wherein said containerincludes a settling tank positioned to receive the liquid dischargedfrom said first linear shaker's liquid output; a baffle modulepositioned within said container, said baffle module situated to receivean output from said settling tank, said baffle module having a dischargeopening; an auger blade positioned at the bottom of said container, saidauger blade adapted to convey the solids in a first direction; a firstpump member, said first pump member having an inlet and an outletdischarge, and wherein said inlet receives the solids from said augerblade; a first cyclone separator receiving the discharge from said firstpump member outlet discharge and delivers a first stream to a secondlinear shaker and a second stream to a possum belly container positionedwithin said setting tank, wherein said second linear shaker has a liquidoutput line directed to said settling tank; a discharge line connectedto said discharge opening from said first baffle module for dischargingthe fluid stream from said container.
 2. The system of claim 1 whereinsaid baffle module comprises a plurality of tilted baffle plates tiltedat an angle between 45 degrees and 70 degrees.
 3. The system of claim 2further comprising a first weir positioned at the baffle module.
 4. Thesystem of claim 3 further comprising a second pump member, said secondpump member having an inlet and an outlet, and wherein said inletreceives the solids from said auger blade and said outlet is directed toa second cyclone separator.
 5. The system of claim 4 further comprisinga mixing compartment operatively connected to said discharge line, saidmixing compartment having a hopper and a mixing blade disposed therein.6. The system of claim 5 wherein said container is mounted to a baseframe, and wherein said base frame contains a set of wheels for mobiletransportation.
 7. An apparatus for separating solids from a fluidstream comprising: a shaker device for separating suspended solids fromthe fluid stream, said shaker device having a fluid output to an initialsettling compartment located within a container, said container having aV-shaped bottom; a baffle plate module positioned within the containerand receiving the output from said initial settling compartment, whereinthe solids from said fluid stream fall to the bottom of the container; aspiral blade positioned at the bottom of the container; a means forrotating said spiral blade at a variable rate; a first pump receivingthe solids from the bottom of the container from said spiral blade, saidfirst pump having an output line; a cyclone means for receiving andseparating the fluid from the solids with a centrifugal force, whereinsaid cyclone means discharges a first fluid to a possum belly containerwithin said initial settling compartment and a first slurry to a secondshaker device for separating said first slurry into a first solid wastestream and to a second fluid stream, and wherein said second shakerdevice discharges the second fluid steam to said baffle plate module; anoutput line extending from said container; a mixing tank, positioned toreceive the output fluid stream from said output line from saidcontainer; said mixing tank having a hopper member operatively connectedthereto, and wherein said mixing tank contains a mixing blade.
 8. Anapparatus for separating solids from a fluid stream comprising: a firstshaker means for receiving the fluid stream and separating suspendedsolids; a first settling tank positioned within a container, saidsettling tank adapted to receive the fluid stream from said first shakermeans; a baffle plate module positioned within the container, saidbaffle plate module receiving the fluid stream from said first settlingtank, said baffle plates being tilted in the direction of fluid flow,wherein said baffle plate module has a discharge line; a spiral bladepositioned at the bottom of the container, said spiral blade havingmeans for rotating said spiral blade at a variable rotation rate, andwherein said spiral blade is oriented in order to direct the slurryalong the bottom of the container in a direction opposite the directionof fluid flow; a first pump receiving the slurry from said spiral blade,said first pump having an output line; a first separator means forreceiving the slurry from said first pump's output line and separatingthe fluid from the solids, said first separator means having a firstliquid output for delivering said fluid stream into said baffle platemodule, and a second liquid output for delivering said fluid steam intosaid first settling tank; an output line from said container.
 9. Theapparatus of claim 8 further comprising: a second pump receiving theslurry from said spiral blade, said second pump having an output line; asecond separator means for receiving the slurry from said second pump'soutput line and separating suspended solids, said second separator meanshaving a first liquid output for delivering said fluid stream into saidbaffle plate module, and a second liquid output for delivering saidfluid stream into said first settling tank.
 10. The apparatus of claim 9further comprising: a mixing tank, positioned to receive the fluidstream from said baffle plate module's discharge line, said mixing tankhaving a hopper member operatively connected thereto, and wherein saidmixing tank contains a mixing blade.
 11. The apparatus of claim 10wherein said baffle plates are disposed at an angle of 55 degrees to 65degrees relative to a vertical ground reference.
 12. The apparatus ofclaim 11 wherein said container is mounted on a frame, and said framecontains a set of wheels for mobile transportation.
 13. The apparatus ofclaim 12 wherein said first separator means comprises: a cyclone devicehaving the first output line for liquids that is directed to a possumbelly container within the first settling tank and a third output linefor solids; a linear shaker device receiving said third output line fromsaid cyclone device and separating liquids to the second output line,said linear shaker device having a fourth output line for disposingsolids to a bin.
 14. The apparatus of claim 13 wherein a secondseparator means comprises: a cyclone device having the first output linefor liquids that is directed to said possum belly container, and a thirdoutput line for solids; a linear shaker device receiving said thirdoutput line from said cyclone device and separating liquids to thesecond output line, said linear shaker device having a fourth outputline for disposing solids to a bin.
 15. A method of treating a fluidcontaining solids comprising: flowing the fluid into a first linearshaker for separating the fluid from the solids, said first linearshaker being associated with a container; discharging the separatedfluid into an initial settling compartment, said initial settlingcompartment being located within said container; channeling the fluidinto a second compartment, said second compartment containing aplurality of tilted baffle plates; settling the solids to the bottom o9fthe container; conveying the solids to a first discharge pump; pumpingthe solids from said discharge pump to a cyclone device in tandem with asecond linear shaker; discharging the fluid stream from said cyclonedevice into a possum belly container positioned within the initialsettling compartment; discharging a slurry stream from said cyclonedevice to said second linear shaker; separating the fluid stream fromsaid slurry stream with said second linear shaker; discharging the fluidstream from said second linear shaker to said second compartment;discharging the solids from said second linear shaker to a bin;suctioning the fluid stream within said container into a mixingcompartment, said mixing compartment adjoining said container; mixing anadditive into said fluid stream within said mixing compartment so that anew slurry is formed.
 16. The method of claim 15 wherein the step ofconveying comprises: rotating a spiral blade and pushing the slurry atthe bottom of the container in an opposite direction from the fluidflow; increasing the rate of rotation of the spiral blade so that anincrease in the solids is delivered to the first discharge pump.
 17. Themethod of claim 16 wherein said first linear shaker includes a wirescreen of 4 mesh.
 18. The method of claim 17 wherein the step ofsuctioning from the container into the missing compartment includessuctioning from the container with a centrifugal pump and discharging toa line containing a mud gun and the method the step of mixing theadditive into said fluid stream comprises: introducing the additivethrough a mixing hopper, said mixing hopper operatively associated withthe mixing compartment; jetting the cleaned fluid from the containerthrough said mud guns within the mixing compartment; rotating aplurality of blades located within said mixing compartment.
 19. Themethod of claim 18 further comprising: a second cyclone means with asecond solid's output line, said second solid's output line beingdelivered to a third linear shaker; and a third solid's output line,said third solid's output line being delivered to said third linearshaker and the method further comprises: discharging the fluid streamfrom said second cyclone means into the possum belly container withinsaid initial settling compartment; and, discharging the solids from saidsecond cyclone means to the third linear shaker.
 20. The method of claim19 wherein said step of conveying the solids includes providing a seconddischarge pump that discharges to said second cyclone means and whereinthe step of rotating said auger blade at6 a variable rate includespushing the solids to said second discharge pump.
 21. The method ofclaim 20 wherein said tilted baffle plates are disposed at an angle ofbetween 45 degrees to 70 degrees.
 22. The method of claim 21 wherein thestep of mixing the additive further includes providing a fourth pumpmeans having a section line operatively associated with the mixing tankand a discharge line operatively associated with said hopper and themethod further comprising: pumping the fluid within said missing tank tosaid hopper via the discharge line; mixing the fluid with the additivein the discharge lien; discharging the mixed fluid and the additive intosaid mixing tank.